Coupling Assembly With Polymer Insert For Panel Rigidity
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Solution Overview
Problem
Existing coupling assemblies for panels lack sufficient rigidity and structural integrity while also being heavy and costly, making them inefficient for panel coupling in manufacturing processes such as vehicle body assembly.
Innovation Solution
A coupling assembly featuring a clip with resilient legs and a polymer insert that enhances structural integrity by urging the legs radially outward, allowing firm contact with the second panel and minimizing weight and cost through the use of materials like polypropylene and polyurethane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional coupling assemblies are used to couple panels together, then the panels can be connected, but the assembly lacks sufficient rigidity and structural integrity
Solution Approach 1:
The coupling assembly uses a composite structure combining a polymer insert (first material) with resilient legs made of a different material (second material). The polymer insert provides structural integrity and rigidity, while the resilient legs provide flexibility and contact force. This composite material approach resolves the contradiction by combining materials with complementary properties to achieve both strength and reliability.
2Reliability
If traditional coupling assemblies are used to couple panels together, then the panels can be connected, but the assembly is heavy and costly
Solution Approach 1:
The coupling assembly uses a polymer insert that can be cost-effectively manufactured and replaced if needed. The polymer material is generally less expensive than metal alternatives, and the simple geometry allows for efficient manufacturing. This approach reduces cost while maintaining reliable panel connection functionality.
Solution Approach 2:
The invention changes the material parameters by using polymer instead of traditional metals, and optimizes the geometric parameters of the resilient legs and insert. This allows achieving the required connection reliability with significantly reduced weight compared to traditional metal coupling assemblies.
3Force
If the coupling assembly uses resilient legs to contact the panel, then firm contact is achieved, but the structural integrity is compromised without an insert
Solution Approach 1:
The polymer insert acts as an intermediary between the resilient legs and the panel hole. It distributes the contact force from the resilient legs over a larger area, preventing stress concentration that would compromise structural integrity. The insert mediates the interaction between the flexible legs and the rigid panel, achieving both firm contact and structural strength.
Solution Approach 2:
The combination of resilient leg material and polymer insert material creates a composite structure where each material compensates for the other's weaknesses. The resilient legs provide contact force while the polymer insert provides structural integrity, resolving the contradiction between force and strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coupling assembly effectively couples panels with enhanced structural integrity, minimizing weight and cost, while allowing for easy assembly and disassembly by utilizing a polymer insert to exert a radially outward force on resilient legs, ensuring secure panel connection.
Implementation Method 1
The insert is at least partially disposed in the clip hole and can be made of a polymer. The insert is configured to enhance the structural integrity of the coupling assembly and, in some embodiments, the insert can be configured to urge the legs radially outward.
Data Source
AI summary
A coupling assembly can couple first and second panels together. The second panel defines a panel hole. The coupling assembly includes a clip configured to be at least partially received in the panel hole. Moreover, the clip extending from the first panel and includes a clip body and at least one resilient leg extending from the clip body. The clip body extends along a longitudinal axis. The clip defines a clip hole extending into the clip body along the longitudinal axis. The coupling assembly further includes an insert comprising a polymer. The insert is at least partially disposed in the clip hole.